As labor shortages and skills gaps persist in the packaging and processing sectors, the industry is increasingly turning to smart technologies and retention strategies to maintain productivity and improve workforce efficiency.
A new white paper, Technology & Workforce: Using Smart Technologies to Bridge the Skills Gap, released by PMMI Business Intelligence, outlines key solutions to address these ongoing challenges. Based on insights from the Vision 2030 sessions at PACK EXPO International in Chicago, the report reveals the top strategies that companies are implementing to mitigate workforce limitations.
Automation and Digital Technology Lead the Way
The report highlights three primary solutions being adopted to overcome labor shortages:
- Automating Changeovers
- App-Based Troubleshooting
- Greater Reliance on Digital Technology
According to the paper, automation is seen as a critical tool to increase efficiency and reduce reliance on manual labor. By automating routine tasks such as machine changeovers, companies can improve uptime and reduce human error. Similarly, app-based troubleshooting is enabling quicker responses to issues on the production floor, reducing downtime and improving overall system performance.
Challenges to Implementation: Budget, Resistance, and Training Needs
While these technologies show promise, there are significant hurdles to widespread adoption. Industry leaders cited concerns such as limited budgets, lack of knowledgeable staff, and the challenge of accessing machine data behind firewalls. Additionally, there is often resistance to change within organizations and substantial training needs to bring teams up to speed on new systems. These factors can hinder the implementation of smart technologies and delay the benefits they offer.
Focus on Employee Retention and Training
With manufacturing worker tenure decreasing to an average of just three years in 2023, the need for effective employee retention strategies has never been more critical. The report emphasizes that to minimize turnover and control training costs, packaging companies must invest in strategies that promote loyalty.
Key tactics include:
- Automating Repetitive Tasks: This allows workers to focus on more strategic tasks, reducing burnout and increasing job satisfaction.
- Empowering Employees: By giving workers more control over their time and career development, companies can foster a more engaged and motivated workforce.
Advanced training methods, such as virtual reality (VR), augmented reality (AR), and video-based learning, are also seen as essential to improving training outcomes. These tools can be personalized to match each worker’s learning style, helping to ensure that all employees, regardless of experience, can quickly adapt to new technologies.
Smart Tools and Advanced Human-Machine Interfaces (HMIs)
The report also highlights the growing role of smart tools in addressing workforce challenges. Intelligent illumination, machine-mounted cameras, and AI-powered systems are providing real-time performance monitoring and increasing troubleshooting efficiency. For example, halo lenses and machine cameras are offering operators visibility inside machines, helping them monitor and maintain performance without the need for disassembly.
Additionally, advanced HMIs are offering a more intuitive interface for operators, including personal assistant avatars and detailed machine diagrams that simplify problem-solving and expedite training. Standardizing these interfaces across different lines and facilities can streamline operations and reduce the learning curve for workers.
Collaboration and AI: The Future of Operations
Another key takeaway from the report is the importance of effective collaboration in improving workforce satisfaction and efficiency. AI-driven collaboration tools are emerging as a means to enhance communication across teams, break down silos, and improve decision-making in real-time.
PACK EXPO Southeast: A Hub for Workforce Solutions
As the packaging industry continues to explore ways to bridge the skills gap, events like PACK EXPO Southeast offer an ideal platform for professionals to learn about the latest innovations in smart technologies. Taking place from March 10–12, 2025, at the Georgia World Congress Center in Atlanta, the event will showcase solutions that address workforce challenges across 40+ vertical markets.
With its proximity to a manufacturing hub, PACK EXPO Southeast is a key opportunity for industry professionals to connect, explore the latest innovations, and learn from leading experts, ultimately shaping the future of packaging workforce solutions.
